high flow safety valves - imi critical · high flow safety valves valve summary size dn 20 to dn...
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Engineering GREAT Solutions
Process and steam safety valves to PED and DIN/EN standards
High Flow Safety Valves
2
High Flow Safety Valves
Valve summary
SizeDN 20 to DN 150
Set Pressureup to16 bar
Material0.6025 / GG25
ApplicationsHeating systems, drinking water, low pressure steam generator
Si 6301
SizeDN 20 to DN 200
Set Pressureup to 40 bar
Material1.0619 and 1.4408
ApplicationsVapours, gases and liquids in all industrial applications
Si 4302
SizeDN 25 to DN 400
Set Pressureup to 250 bar
Material1.0619, 1.4408 and 1.7357
ApplicationsProtection of system components at high pressure or large mass flow, for power plants and industrial steam generators
Si 6303-05
SizeDN 80 to DN 300
Set Pressureup to 200 bar
Material1.0619, 1.7357 and 1.7379
ApplicationsBoiler and superheater in power plants and industrial steam generators
Si 6106
Options
3
Contents 04 Useful knowledge
06 Si 6301
06 Features, applications, approvals and standards Si 6301
07 Type code Si 6301
08 Coefficients of discharge Si 6301
10 Material code Si 6301
11 Sizes, pressure ranges and dimensions Si 6301
12 Si 4302
12 Features, applications, approvals and standards Si 4302
13 Type code Si 4302
14 Coefficients of discharge Si 4302
16 Material code Si 4302
18 Sizes, pressure ranges and dimensions Si 4302
20 Si 6303 / Si 6304 / Si 6305
20 Features, applications, approvals and standards Si 6303 / Si 6304 / Si 6305
21 Type code Si 6303 / Si 6304 / Si 6305
22 Coefficients of discharge Si 6303 / Si 6304 / Si 6305
24 Material code Si 6303
26 Sizes, pressure ranges and dimensions Si 6303
28 Material code Si 6304
30 Sizes, pressure ranges and dimensions Si 6304
32 Material code Si 6305
34 Sizes, pressure ranges and dimensions Si 6305
36 Si 6106
36 Features, applications, approvals and standards Si 6106
37 Type code Si 6106
38 Coefficients of discharge Si 6106
39 Weld end (option .22) Si 6106
40 Material code Si 6106
42 Sizes, pressure ranges and dimensions Si 6106
44 Trim code
45 Controlled safety pressure relief system
46 Safety valve with heating jacket (Option .18)
47 Technical design options
4
High Flow Safety Valves
Safety valves have the function of prevent-ing inadmissible overpressure in pipe systems, pressure vessels and boilers, in order to avoid danger to people, plant and the environment. They are set to a higher pressure than the operating pressure of the system to be protected.
Safety valves …
… open once the set pressure is reached.
… steady discharge the required mass flow.
… close after the pressure has dropped.
Safety valves for pressure systems with low mass flow or where the mass flow is of marginal importance, e.g. with thermal expansion, are grouped in the IMI Bopp & Reuther application category “Regular Flow”.
The application category “Proportional Flow” comprises safety valves with proportional functional characteristics for special operating conditions.
In the IMI Bopp & Reuther application category “High Flow”, the required capacity is usually the most important criteria for selecting a size. With reference to the inlet size, high flow valves can discharge the highest capacity and in particular on gas/vapour service open rapidly for instant pressure relief.
The size of the outlet is always larger than that of the inlet, in order to provide the fluid room for supercritical relief in the discharge. This way the back pressure building up in the body, which may affect the safe function, will not become excessively high.
> Feature Inlet sizes DN 20 to DN 400, up to 15
body seat sizes per pressure rating
Benefit The variety of versions within the
pressure ratings, temperature classes and sizes provides for a flexible choice helping to answer industrial requirements at low cost.
> Feature One-trim design for vapours, gases
and liquids. Only the spring selected for optimal function may be different.
Benefit Easy to use the same valve when
operating conditions change, as well as operational reliability in 2-phase flow. Reduction of spare part inventories and inexpensive maintenance.
> Feature Maximum lift with lift stop for the
certified capacity
Benefit Stable position of the disc at full lift
> Feature Bellows inside bonnet spacer outside
the flow
Benefit Bellows is protected from the flow
impact, hence increased service life
> Feature One-piece spindle, valve disassembly
possible without set pressure change
Benefit Easy maintenance and repair
> Feature Supplementary special designs for the
best possible safety valve configuration.
Benefit Optimal adjustment of the safety valve
to the operating conditions and function requirement
Features and benefits
Useful knowledge
Cap
acit
y
“Proportio
nal Flow”
“High Flow”
“Regular Flow”
Pressure
5
Conventional safety valve
The IMI Bopp & Reuther series Si 43 and Si 63 are most commonly used in process plants. The closed spring bonnet traps the process fluid in the valve and prevents a release to the environment. The straightforward construction and reliable guidance of the stainless steel inside parts ensure free and repeated discharge cycles. Conventional safety valves are usually selected where a short outlet pipe leads to the atmosphere, where the fluid is safely discharged into low pressure systems and where the fluid is non-critical.
The conventional safety valve limit for built-up back pressure is given for each type in this catalogue. In case of constant superimposed back pressure, a conventional safety valve is set to the differential pressure (p-pb).
Safety valve with bellows
The Si 44 and Si 64 series are equipped with bellows between the body and bonnet. The following conditions require the selection of bellows:
> Excessive built-up back pressure or variable superimposed back pressure. The bellows has a balancing effect on the back pressure.
> When the fluid is highly viscous or contains solid particles that could enter the guiding areas. The bellows protects the guides.
> When the fluid could have a corrosive effect on the inner parts. The bellows separates the bonnet chamber from the flow.
> In case of media with a very high temperature. The bellows shields the spring against overheating.
Safety valve with open bonnet
In the safety valve series Si 41 and Si 61, the spring bonnet has an open design. The resulting ventilation of the bonnet chamber permits a standard steel spring to be used in fluid temperatures up to 400°C. The lifting lever makes this design particularly suitable for steam applications.
In higher temperatures, a bonnet spacer between the body and bonnet can provide the spring with further protection from overheating (design option .15), or a bellows can be additionally integrated as the best possible measure (type Si 45 and Si 65).
Safety valve with bellows
Safety valve with open bonnet
Conventional safety valve
6
Si 6301
High Flow Safety Valves
Cost-efficient IMI Bopp & Reuther low pressure safety valve:
> Semi nozzle design
> Cast iron body with stainless steel inner parts (except for spring and spring washer)
Features
Inlet sizesDN 20 to DN 150
Inlet pressure ratingPN 10 to PN 16
Set pressures0.45 bar g up to 16 bar g
Temperature range-10 °C to + 300 °C
OverpressureVapours / gases 5%Liquid 10%
Blow downVapours / gases 10%Liquids 20%
Allowable built-up back pressure15% of the set pressure
> For vapours, gases and liquids
> Hot water from heat generation plants in full acc. to TRD 721, EN 12828 with admissible supply temperatures up to 120 °C (acc. to TÜV certification 660)
> Steam applications up to PN 16
> Potable water
Applications
Approvals and standards
EC type examination
- Pressure Equipment Directive 97 / 23 / EC
- DIN EN ISO 4126-1
- AD 2000-Merkblatt A2
- VdTÜV Merkblatt “Sicherheitsventil 100”
VdTÜV type approval acc. to
TÜV.SV.12-1134.d0.D / G / F.aw.p
TÜV.SV.12-660.d0.D / G / H.aw.p
TÜV.SV.13-701.d0.F.aw.p
IMI Bopp & Reuther will not renew the existing VdTÜV type approvals. The requirements by VdTÜV and applicable standards are completely considered by the EC type examination.
The design, manufacture, testing and labelling meet the require ments of DIN EN ISO 4126-7, DIN EN 12266-1 / -2 (insofar as applicable to safety valves), DIN EN 1092 parts I and II Flanges, AD 2000-Merkblatt A4, AD 2000-Merkblatt HP0, technical rules for steam boiler TRD 108, TRD 110, TRD 421
Basic valve for low pressure
Economic for Heating system and water use
7
Si 6301
Type
Please state
Type code Order example
1 Series Si 6 DIN/EN valve Si 6
2 Design 3 Conventional, closed bonnet 3
3 Characteristic 0 High capacity "High Flow" 0
1 Proportional acting ”Proportional Flow”
4 Pressure class 1 Up to PN 16 1
5 Cap A Packed lifting lever A
AB Packed lifting lever with test gag
6 Material code 05 EN-GJL-250 / 5.1301 GG25 / 0.6025 / EN-JL 1040
05
7 Options .09 Locking sleeve (government ring) .11a
.11a Disc with soft seal EPDM
.35 Lift restriction ring
.57 Weight loading
.58 Diaphragm seal
Si 6301 A 05 .11a
Set pressure 8.0 bar gFluid temp. 80 °CFluid Water, and State Liquid Inlet DN 50, PN 16, B1 Outlet DN 80, PN 10, B1Flow diameter 40 mmApproval 97 / 23 / EG (CE)
Type code
The special design with diaphragm seal (option .58) serves to tightly seal the spring chamber and guides, as well as protecting the sliding parts. The spring bonnet is equipped with a 10 mm diameter vent opening. Option .58 is usually selected for safety valves in heating technologies.
Diaphragm body seal
8
Si 6301
High Flow Safety Valves
The coefficient of discharge for gases / vapours in a pressure ratio of pb / p0 > 0.25 is shown in the diagram below.
The capacity of the selected safety valves can be adjusted to the required capacity by reducing the lift, thus reducing undesirable extra performance.he following applies: aw(reduced) = aw x qm / qmc .
The required ratio h/d0 is shown in the diagram below, and the reduced lift calculated with h(reduced) = d0 x (h / d0).
Si 6301 coefficient of discharge aw depending on h/d0 for gases and vapours
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.10 0.15 0.20 0.25 0.30 0.35 0.40
αw
[−]
h/d0 [−]
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.10 0.15 0.20 0.25 0.30 0.35 0.40
d0 = 16-77 mm d0 = 93-110 mm
0.10 0.15 0.20 0.25 0.30 0.35 0.40
h/d0[–]
0.9
0.8
0.7
0.6
0.5
0.4
0.3
aw[–
]
Si 6301 coefficient of discharge aw depending on pb/p0 for gases and vapours
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
αW
[−]
pa/p0 [−]
d0 = 16-110
0.9
0.8
0.7
0.6
0.5
0.4
0.3
pb/p0[–]
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
aw[–
]
Fluid group Inlet size Flow diameter h/d0 ≥ pb/p0 ≤ aw
Vapours / gases (D / G)DN 20 to DN 100
DN 125 to DN 150
16 mm to 77 mm
93 mm to 110 mm
0.34
0.36
0.25
0.25
0.78
0.78
Liquids (F)
DN 20 to DN 80
DN 100
DN 125 to DN 150
16 mm to 63 mm
77 mm
93 mm to 110 mm
0.34
0.36
0.36
-
-
-
0.6
0.6
0.52
Coefficients of discharge
9
Si 6301
Si 6301 coefficient of discharge aw depending on h/d0
for liquid
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.10 0.15 0.20 0.25 0.30 0.35 0.40
αw
[−]
h/d0 [−]
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.10 0.15 0.20 0.25 0.30 0.35 0.40
d0 = 16-63 mm d0 = 77 mm d0 = 93-110 mm
0.10 0.15 0.20 0.25 0.30 0.35 0.40
h/d0[–]
0.8
0.7
0.6
0.5
0.4
0.3
0.2
aw[–
]
h = Lift [mm]d0 = Flow diameter of the selected safety valve [mm]h/d0 = Lift / Flow diameter ratiopb = Absolute back pressure [bar a]p0 = Absolute relieving pressure [bar a]pb/p0 = Absolute back pressure / absolute relieving pressure ratioaw = Coefficient of discharge acc. to AD 2000-Merkblatt A2qm = Required mass flow [kg/hr]qmc = Certified mass flow [kg/hr]
The safety valve type Si 6x11 is designed for liquid service with the specific requirement of a “proportional opening characteristic”. This specification is certified by a particular EC approval. With the lift / flow diameter ratio of h/d0 > 0.16; the corresponding coefficient of discharge is aw 0.36.
The coefficients of discharge Kdr acc. to DIN EN ISO 4126-1 for this valve series are identical with above coefficients of discharges aw and the values in the diagrams.
Coefficient of discharge for hot water applications
Set Pressure [bar g] Coefficient of discharge aw
1.0 0.69
1.5 0.74
2.0 0.76
2.5 to 10 0.78
The corresponding interim values for the set pressure range from 1 bar to < 2.5 bar need to be interpolated. Applicable for h/d0 ≥ 0.36.
Safety valves intended for discharging hot water from heat generation units or plants are approved in a separate EC type examination. The coefficients of discharge are given in the below table. The set pressure is limited to a 1 bar g to 10 bar g range.
10
Si 6301
23
24
1617
18143015
43513121011622872
1
19
High Flow Safety Valves
Material code 05
Temperature application range -10 °C to +300 °C
Part Name Material
1 Body EN-GJL-250 / 5.1301 GG25 / 0.6025 / EN-JL 1040
2 Seat bushing 1.4122
3 Stud, short 5.6
4 Stud, long 5.6
5 Hexagon nut 5
6 Disc holder 0.7040
7 Disc 3) 1.4122
8 Disc retainer 1.4571
10 Flat gasket 1.4401 / graphite
11 Intermediate cover 1) 1.4122 1.4059
12 Pressure sleeve 1.4122
13 Spring washer, bottom 1.0038
14 Spring washer, top 1.0038
15 Bonnet EN-GJL-250 / 5.1301 GG25 / 0.6025 / EN-JL 1040
16 Adjusting screw 1.4104
17 Lock nut 5
18 Spindle 1.4021
19 Flat gasket 1.4401 / graphite
22 Pressure ring 1.4122
23 Packed lifting lever (cap) 2)
0.7040
24 Lifting nut 1.4021
30 Spring 4) 1.1200 1.8159
1) Intermediate cover for DN 80 made from 1.4122, above that made from 1.4059
2) Packed lifting lever (cap) from DN 150 flanged
3) Disc material may be upgraded to stellated 1.4571 upon request for safety valves in saturated steam service
4) The spring material selection depends on the valve size and set pressure.
IMI Bopp & Reuther reserve the right to technical changes or application of higher quality materials without prior notice. The material design can be tailored to customer specifications at any time upon request.
Material code
11
Si 6301
H1
S1
S2
Si 6301
SizeDNE 20 25 32 40 50 65 4) 80 100 125 150
DNA32 40 50 65 4) 80 100 125 150 200 250
Flow diameter [mm] d0
16 20 25 32 40 50 63 77 93 110
Flow area [mm²] A0
201 314 491 804 1257 1964 3117 4657 6793 9503
Min. set pressure [bar g]
0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45
Max. set pressure1)
[bar g]16 16 16 16 16 16 16 16 12.5 10
Max. back pressure
[bar g]4 4 4 4 4 4 4 4 3 2.5
Inlet flange DIN EN 2)
PN 10
PN 16
Outlet flange DIN EN 2)
PN 10
PN 16
Centre to face dimension S1 [mm]
85 95 100 115 125 140 155 175 215 225
Centre to face dimension S2 [mm]
95 105 110 130 145 150 170 180 220 245
Height H1 [mm]
355 405 430 510 565 675 725 825 875 1020
Drain size E 3) G¼ G¼ G¼ G¼ G¼ G⅜ G⅜ G⅜ G½ G1/2
Weight [kg]
8 10 13 19 25 37 50 74 95 140
1) Stated values are maximum values corresponding to the spring forces. The component strength may need to be reviewed depending on the material and temperature.
2) Flanges PN 10 / 16 acc. to DIN EN 1092-2; flange facing Type B1
3) Drain E is only drilled into the body if condensate formation is to be expected.
4) 4-hole flange drilling for DN 65 PN 10 / 16
Sizes, pressure ranges and dimensions
12
Si 4302
High Flow Safety Valves
The state-of-the-art IMI Bopp & Reuther medium-pressure safety valve:
> Cost-effective semi nozzle body design with seat bushing
> Developed in modular design with other series
> Reliable function with ideal capacity
> Inner parts made from stainless steel (except for spring and spring washer)
Features
Inlet sizesDN 20 to DN 200
Inlet pressure ratingPN 10 to PN 40
Set pressures0.1 bar g to 40 bar g
Temperature range-270 °C to + 450 °C
OverpressureVapours / gases 5%Liquids 10%
Blow downVapours / gases 10%Liquids 20%
Allowable built-up back pressure without bellows20% of the set pressure
> For vapours, gases and liquids
> Protection of pressure vessels
> Protection of heat exchangers
> Protection of system components
> Suitable for all industrial applications
> Chemical industry
> Petrochemical industry
> Technical gases
> Cooling and oxygen applications
> Power generation and power supply
> Steam boiler up to PN 40
Applications
Approvals and standards
EC type examination
- Pressure Equipment Directive 97 / 23 / EC
- DIN EN ISO 4126-1
- AD 2000-Merkblatt A2
- VdTÜV Merkblatt “Sicherheitsventil 100”
VdTÜV type approval acc. to
TÜV.SV.13 -1094.d0.D / G / F.aw.p
IMI Bopp & Reuther will not renew the existing VdTÜV type approvals. The requirements by VdTÜV and applicable standards are completely considered by the EC type examination.
The design, manufacture, testing and labelling meet the require ments of DIN EN ISO 4126-7, DIN EN 12266-1 / -2 (insofar as applicable to safety valves), DIN EN 1092 parts I and II Flanges, AD 2000-Merkblatt A4, AD 2000-Merkblatt HP0, technical rules for steam boiler TRD 110, TRD 421
Engineered with high discharge
Optimum engineered operation for easy piping
Single Trim for Steam, Gases, Liquids
13
Si 4302
Type code Order example
1 Series Si 4 Safety valve for high capacities Si 4
2 Design 1 Conventional, open bonnet 4
3 Conventional, closed bonnet
4 Bellows, closed bonnet
5 Bellows, open bonnet
3 Characteristic 0 High capacity "High Flow" 0
4 Pressure class 2 Up to PN 40 2
5 Cap G Gastight cap A
GB Gastight cap with test gag
A Packed lifting lever
AB Packed lifting lever with test gag
AK Pneumatic actuator
6 Material code 00 GP240GH / 1.0619 04
04 GX5CrNiMo19-11-2 / 1.4408
7 Options .09 Locking sleeve (government ring) .59
.11t Disc with soft seal PTFE
.14a Lift indication with inductive proximity switch in the cap
.14b Lift indication with inductive proximity switch in the auxiliary housing
.14c Lift indication with inductive proximity switch for exposed spindle with actuator AK
.15 Bonnet spacer for high and low temperatures
.18 Heating jacket
.25 Block body design
.28 Oil and grease free
.32 Purge connection
.35 Lift restriction ring
.38 Vibration damper
.57 Weight loading
.59 Stellited disc
.60 Stellited seat
Si 4402 A 04 .59
Set pressure 18 bar gFluid temp. 20 °CFluid Air, and State GasInlet DN 50, PN 40, B1Outlet DN 80, PN 16, B1Flow diameter 42 mmApproval 97 / 23 / EG (CE)
Type
Please state
Type code
14
High Flow Safety Valves
Fluid group Inlet size Flow diameter h/d0 ≥ pb/p0 ≤ aw
Vapours / gases (D / G) DN 20 to DN 200 17 mm to 156 mm 0.33 0.2 0.81
Liquids (F) DN 20 to DN 200 17 mm to 156 mm 0.33 - 0.57
Si 4302
The coefficient of discharge for gases / vapours in a pressure ratio of pb / p0 > 0.2 is shown in the diagram below.
The capacity of the selected safety valves can be adjusted to the required capacity by reducing the lift, thus reducing undesirable extra performance. The following applies:
aw(reduced) = aw x qm/qmc. The required ratio h/d0 is shown in the diagram below, and the reduced lift calculated with h(reduced) = d0 x (h/d0).
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
αW
[−]
pa/p0 [−]
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
aw
[–]
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Pb/P0[–]
d0 = 17-156 mm
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
αw
[−]
h/d0 [−]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.400.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
h/d0[–]
d0 = 17-156 mm
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
aw
[–]
d0 = 17-156 mm
Si 4302 coefficient of discharge aw depending on h/d0 for gases and vapours
Si 4302 coefficient of discharge aw depending on pb/p0 for gases and vapours
Coefficients of discharge
15
Si 4302
Si 4302 coefficient of discharge aw depending on pb/p0 for liquid
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
αw
[−]
h/d0 [−]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.400.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
h/d0[–]
0.9
0.8
0.7
0.6
0.3
0.2
0.1
0.0
aw
[–]
d0 = 17-156 mm
0.4
0.5
The coefficients of discharge Kdr acc. to DIN EN ISO 4126-1 for this valve series are identical with above coefficients of discharge aw and the values in the diagrams.
h = Lift [mm]d0 = Flow diameter of the selected safety valve [mm]h/d0 = Lift / Flow diameter ratiopb = Absolute back pressure [bar a]p0 = Absolute relieving pressure [bar a]pb/p0 = Absolute back pressure / absolute relieving pressure ratioaw = Coefficient of discharge acc. to AD 2000-Merkblatt A2qm = Required mass flow [kg/hr]qmc = Certified mass flow [kg/hr]
Fluid air
Temperature T020 °C = 293.15 K
Isentropic exponent k1.4
Molar mass M29.0 kg / kmol
Compressibility factor Z1.0
Set pressure1.5 bar g
Relieving pressure p0 at 10% accumulation(1.5 x 1.1) + 1 = 2.65 bar a
Back pressure pbatmospheric
Required capacity qm6.000 kg / hr
pb/p0 = 0.377 can be used to derive the coefficient of discharge Kdr = 0.757 from the diagram “Si 4302 coefficient of discharge aw depending on pb/p0 for gases and vapours”. (aw is equal Kdr )As the condition for critical flow
pb ≤ 2
p0 k+1
k k-1 A =
qm
p0 C Kdr
M Z T0
A = 6000
= 3,518.1 mm2
2.65 x 2.703 x 0.757 29 1 x 293.15
k 2
k+1
k+1 k-1
With C = 3.948 = 2.703, is
is met in the example, the following applies:
, is the required flow area.
With a flow area of A0 = 4902 mm², the safety valve Si 4302 A 00, DN 100 x 150, PN 10 x 10, d0 79.0 mm is suitable for this application (see page 18 for size range).
Sample size calculation for a safety valve in gas service acc. to DIN EN ISO 4126-7:
16
Si 4302
23
24
20
17
19
16
14
15
18
30
4
3
5
13
12
1011229
87
6
2
1
2955
High Flow Safety Valves
Bellows design Si 4402
Material code
17
Si 4302Material code 00 04
Temperature application range -10 °C to +450 °C 1) -200 °C to +400 °C 2)
Part Name Spare part Material Material
1 Body 1.0619 1.4408
2 Seat bushing 1.4122 1.4571
3 Stud, short 1.1181 A4-70
4 Stud, long 1.1181 A4-70
5 Hexagon nut 04 A4-70
6 Disc holder 1.4021 1.4571
7 Disc *2, 3 1.4571 1.4571
8 Disc retainer 1.4571 1.4571
9 Ball Stainless steel Ceramic
10 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite
11 Intermediate cover 1.4122 1.4571
12 Pressure sleeve 1.4122 1.4571
13 Spring washer, bottom 1.0460 1.4571
14 Spring washer, top 1.0460 1.4571
15 Bonnet 1.0619 1.4408
16 Adjusting screw 1.4571 1.4571
17 Lock nut 1.4104 1.4571
18 Spindle 1.4021 1.4571
19 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite
20 Hex socket head screw 8.8 A4-70
22 Pressure ring 1.4571 1.4571
23 Packed lifting lever (cap) 1.0619 1.4408
24 Lifting nut 1.4404 1.4571
29 Bonnet spacer 1.0619 1.4408
30 Spring 3) *3 1.1200 1.8159
1.4310 1.8159, chem. nickel plated
55 Bellows *3 1.4571 1.4571
1) Material may be used in temperatures down to -85 °C if the specification of AD 2000-Merkblatt W10 is complied with.
2) Material may be used in temperatures down to -273 °C if the specification of AD 2000-Merkblatt W10 is complied with.
3) The spring material selection depends on the valve size and set pressure as well as the temperature. Other spring materials are available for special operating conditions, e.g. temperatures > 400 °C or < -170 °C, and if the customer specifies this.
Spare Parts:*1 For start-up*2 For 2 years of operation*3 After several years of operating
IMI Bopp & Reuther reserve the right to technical changes or application of higher quality materials without prior notice. The material design can be tailored to customer specifications at any time upon request.
18
Si 4302
High Flow Safety Valves
SizeDNE 20 25 32 40 40 40 50 65 3) 80 80 80 100 125 150 150 200 200
DNA32 40 50 50 65 3) 80 80 100 100 125 150 150 200 200 250 250 300
Flow diameter [mm] d0
17 22 27.5 27.5 35 35 42 52 52 65 65 79 93 93 112 125 156
Flow area [mm²] A0
227 380 594 594 962 962 1385 2124 2124 3318 3318 4902 6793 6793 9852 12272 19113
Min. set pres-sure [bar g]
Si 41 / Si 430.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49 0.49
Si 4302.57 1) 0.25 0.2 0.1 0.1 0.13 0.13 0.13 0.16 0.16 0.11 0.11 0.13 0.15 0.18 0.15 0.16 0.15
Si 44 / Si 45 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
Max. set pressure1)
[bar g]40 40 40 40 32 32 32 32 32 25 25 20 20 20 25 15 14
Max. back pres-sure 2) [bar g]
16 16 16 16 16 16 16 16 16 10 10 10 7 7 7 4 4
Inlet flange DIN EN 4) PN 10 - 40 (with flange thickness as per PN 40)
PN 10 /16 (DN 200 PN 16 with flange thickness as per PN 25)
PN 25 / 40 PN 25
Outlet flange DIN EN 4) PN 10 - 40 PN 10 /16 PN 10
Centre to face dimension S1 [mm]
85 95 100 100 115 115 125 140 140 155 155 175 215 215 225 240 265
Centre to face dimension S2 [mm]
95 105 110 110 130 130 145 150 150 170 170 180 220 220 245 270 290
Height H1 [mm] 410 425 435 435 522 522 576 690 690 740 740 840 1030 1030 1195 1225 1320
Height H2 [mm] 470 480 480 480 572 572 626 750 750 810 810 920 1135 1135 1325 1355 240
Additional height H3 f. actuator AK [mm]
222 222 222 222 310 310 310 267 267 267 267 267 394 394 240 240 240
Drain size E 5) G¼ G¼ G¼ G¼ G¼ G¼ G¼ G⅜ G⅜ G⅜ G⅜ G⅜ G½ G½ G½ G¾ G¾
Weight Si 41/43 [kg]
9 12 14 14.5 19 21 27 40 43 55 58 84 104 108 148 183 240
Weight Si 44/45 and Si 41/43.15 [kg]
11 14 17 17.5 22 25 31 44 47 60 63 92 112 122 178 213 270
Additional weight actuator AK [kg]
12 12 12 12 37 37 37 37 37 37 37 37 76 76 80 80 80
1) Set pressure if the direct weight load option .57 is used.
2) Stated values are maximum values corresponding to the spring forces. The component strength
may need to be reviewed, and a suitable pressure rating selected, depending on the material and temperature.
3) 4-hole flange drilling with DN 65 PN 10 / 16
4) Flanges PN 10 - 40 acc. to DIN EN 1092-2; facing type B1
5) Drain E is only drilled into the body if condensate formation is to be expected.
Sizes, pressure ranges and dimensions
19
H2
S1
S2
K
Si 4402 Si 4502
Si 4302 Si 4102
H1
S1
S2
H3
Si 4302
B
A E
D
Lø
C
Support brackets
Size DNE × DNA
A B C D E LSupport bracket thickness
Number of screws
40 x 65 180 84 134 60 150 14 10 4 x M 12
40 x 80 180 84 134 60 150 14 10 4 x M 12
50 x 80 210 93 160 65 175 14 12 4 x M 12
65 x 100 245 94 196 65 210 14 12 4 x M 12
80 x 100 245 94 196 65 210 14 12 4 x M 12
80 x 125 300 115 240 85 265 18 15 4 x M 16
80 x 150 320 150 280 125 290 18 15 4 x M 16
100 x 150 320 150 280 125 290 18 15 4 x M 16
125 x 200 365 120 300 85 325 18 15 4 x M 16
150 x 200 365 120 300 85 325 18 15 4 x M 16
150 x 250 415 150 360 115 375 18 15 4 x M 16
200 x 250 455 180 400 145 415 18 15 4 x M 16
200 x 300 510 180 450 145 465 22 20 4 x M 20
Dimensions in mm
Actuator AK
The height from the inlet to the lower edge of the support bracket is identical with the centre to face dimension S2.
Support brackets will only be drilled if specified by the customer.
The bonnet for bellows seal design is provided with the test connection K. K up to DN 50 x 80 – G¼”, above G⅜”.
Support brackets
20
Si 6303 / Si 6304 / Si 6305
High Flow Safety Valves
The proven quality IMI Bopp & Reuther high-pressure safety valve:
> A reliable design with solid inlet nozzle, screwed in and welded
> With a great variety of sizes and options
> Available in material designs for high as well as low temperatures
Features
Inlet sizesDN 25 to DN 400
Inlet pressure ratingPN 10 to PN 400
Set pressures0.45 bar g to 250 bar g
Temperature range-270 °C to + 550 °C
OverpressureVapours / gases 5%Liquids 10%
Blow downVapours / gases 10%Liquids 20%
Allowable built-up back pressure15% of the set pressure
> For vapours, gases and liquids
> Protection of system components
> Steam boiler
> Air separator
> Power plants and industrial steam generation
> Paper factories
> High-pressure chemical processes
Applications
Approvals and standards
EC type examination
- Pressure Equipment Directive 97 / 23 / EC
- DIN EN ISO 4126-1
- AD 2000-Merkblatt A2
- VdTÜV Merkblatt “Sicherheitsventil 100”
VdTÜV type approval acc. to
TÜV.SV.12 -1134.d0.D / G / F.aw.p
TÜV.SV.13 -701.d0.F.aw.p
IMI Bopp & Reuther will not renew the existing VdTÜV type approvals. The requirements by VdTÜV and applicable standards are completely considered by the EC type examination.
The design, manufacture, testing and labelling meet the requirements of DIN EN ISO 4126-7, DIN EN 12266-1 / -2 (insofar as applicable to safety valves), DIN EN 1092 parts I and II Flanges, AD 2000-Merkblatt A4, AD 2000-Merkblatt HP0, technical rules for steam boiler TRD 110, TRD 421
Full nozzle design
Engineered for high pressure protection
21
Si 6303 / Si 6304 / Si 6305
Type code Order example
1 Series Si 6 DIN/EN Full lift valve Si 6
2 Design 1 Conventional, open bonnet 1
3 Conventional, closed bonnet
4 Bellows, closed bonnet
5 Bellows, open bonnet
3 Characteristic 0 High capacity "High Flow" 0
1 Proportional acting ”Proportional Flow”
4 Pressure class 3 max. PN 160 (up to 62 bar g) 4
4 max. PN 160 (up to 95 bar g)
5 max. PN 400
5 Cap G Gastight cap AB
GB Gastight cap with test gag
A Packed lifting lever
AB Packed lifting lever with test gag
AK Pneumatic actuator
6 Material code 2) 00 GP240GH / 1.0619 00
01 G17CrMo5-5 / 1.7357
04 GX5CrNiMo19-11-2 / 1.4408
7 Options .09 Locking sleeve (government ring) .22a .60
.11a Disc with soft seal EPDM (pressure class 3 only)
.14a Lift indication with inductive proximity switch in the cap
.14b Lift indication with inductive proximity switch in the auxiliary housing
.14c Lift indication with inductive proximity switch for exposed spindle with actuator AK
.15 Bonnet spacer for high and low temperatures
.18 Heating jacket
.22a 1) Weld end at inlet
.22b Weld end at outlet
.25 Block body design
.28 Oil and grease free
.32 Purge connection
.35 Lift restriction ring
.38 Vibration damper
.59 Stellited disc
.60 Stellited seat
1) For valves with weld ends, please state the pipe’s outer diameter, wall thickness and joint type code in the order. See page 39 for information on standard dimensions.
2) The standard materials of the material codes can be changed by selecting trim codes. Please see page 44 for information on the trim codes T1, T2, T3.
Si 6104 AB 00 .22a .60
Set pressure 38 bar gFluid temp. 360 °CFluid Superheated steam, and State SteamInlet DN 100, weld endWeld end dimensions1) 117 x 5.6 mm Outlet DN 150, PN 40, B1Flow diameter 63 mmApproval 97 / 23 / EG (CE)
Type
Please state
Type code
22
Si 6303 / Si 6304 / Si 6305
High Flow Safety Valves
Fluid group Inlet size Flow diameter h/d0 ≥ pb/p0 ≤ aw
Vapours / gases (D / G)
DN 25 to DN 150
DN 125 to DN 200
DN 200 to DN 300
DN 300 to DN 400
16 mm to 77 mm
86 mm to 110 mm
117 mm to 180 mm
200 mm to 280 mm
0.34
0.36
0.36
0.36
0.25
0.25
0.3
0.3
0.78
0.78
0.74
0.71
Liquids (F)
DN 25 to DN 100
DN 100 to DN 150
DN 125 to DN 200
16 mm to 70 mm
77 mm
86 mm to 125 mm
0.34
0.36
0.36
-
-
-
0.6
0.6
0.52
The coefficient of discharge for gases / vapours in a pressure ratio of pb/p0 > 0.25 and/or pb/p0 > 0.3 is shown in the diagram below.
The capacity of the selected safety valves can be adjusted to the required capacity by reducing the lift, thus reducing undesirable extra performance. The following applies:
aw(reduced) = aw x qm/qmc. The required ratio h/d0 is shown in the diagram below, and the reduced lift calculated with h(reduced) = d0 x (h / d0).
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.10 0.15 0.20 0.25 0.30 0.35 0.40
αw
[−]
h/d0 [−]
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.10 0.15 0.20 0.25 0.30 0.35 0.40
d0 = 16-77 mm d0 = 86-110 mm d0 = 117-180 mm d0 = 200-280 mm
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
αw
[−]
h/d0 [−]
Si 6: d0Ø 12−77
Ø 86−110Ø 117−180Ø 200−280
0.10 0.15 0.20 0.25 0.30 0.35 0.40
h/d0[–]
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
aw[–
]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
αW
[−]
pa/p0 [−]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
aw
[–]
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
Pb/P0[–]
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
d0 = 16-110 mm d0 = 117-180 mm d0 = 200-280 mm
Si 6303 / Si 6304 / Si 6305 coefficient of discharge aw depending on h / d0 for gases and vapours
Si 6303 / Si 6304 / Si 6305 coefficient of discharge aw depending on pb/p0 for gases and vapours
Coefficients of discharge
23
Si 6303 / Si 6304 / Si 6305
Si 6303 / Si 6304 / Si 6305 coefficient of discharge aw depending on h / d0 for Liquid
The coefficients of discharge Kdr acc. to DIN EN ISO 4126-1 in this series are identical with above coefficients of discharge aw and the values in the diagrams.
The safety valve type Si 6x13/ Si 6x14/ Si 6x15 is designed for liquid service with the specific requirement of a “proportional opening characteristic”. This specification is certified by a particular EC approval. With the lift / flow diameter ratio of h/d0 > 0.16; the corresponding coefficient of discharge is aw 0.36.
h = Lift [mm]d0 = Flow diameter of the selected safety valve [mm]h/d0 = Lift / Flow diameter ratiopb = Absolute back pressure [bar a]p0 = Absolute relieving pressure [bar a]pb/p0 = Absolute back pressure / absolute relieving pressure ratioaw = Coefficient of discharge acc. to AD 2000-Merkblatt A2qm = Required mass flow [kg/hr]qmc = Certified mass flow [kg/hr]
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.10 0.15 0.20 0.25 0.30 0.35 0.40
αw
[−]
h/d0 [−]
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.10 0.15 0.20 0.25 0.30 0.35 0.400.10 0.15 0.20 0.25 0.30 0.35 0.40
h/d0[–]
0.8
0.7
0.6
0.5
0.4
0.3
0.2
d0 = 16-70 mm d0= 77 mm d0 = 86-125 mm
aw
[–]
Fluid oil
Density700 kg / m³
Temperature T056 °C = 329 K
Set pressure48.0 bar g
Relieving pressure p0 at 10% accumulation(48 x 1.1) + 1 = 53.8 bar a
Back pressure pb15 bar a
Required capacityt qm51.000 kg / hr
For rather small sizes, the coefficient of discharge Kdr = 0.6 can be derived from the table on page 22 for liquids.
Sample size calculation for a safety valve in liquid service acc. to DIN EN ISO 4126-7:
With a flow area of A0 = 491 mm², the safety valve Si 6303 G 00, DN 40 x 50, PN 63 x 16, d0 25.0 mm is suitable for this application (see page 26 for the size range). The certified capacity qmc can be established as 78.146.9 kg/hr from above equation. The lift can be restricted to reduce the undesirable extra performance (qmc/qm) of 53%. aw(reduced) = aw x qm/qmc = 0.6 x 51.000/78.146.9 = 0.39. The ratio h/d0 can be derived from the diagram as 0.18, which makes the restricted lift h = 0.18 x 25 = 4.5 mm.
The specific volume v = 1/density = 0.0014285
A = qm
1.61 Kdr kv
v p0- pb
A = 51000 0.0014285 1.61 x 0.6 x 1.0 53.8 - 15
= 320.35 mm²
As the viscosity is negligible in this example, kv = 1.0 can be used in the calculation.
, is the required flow area.
24
Si 6303
23
24
2017
1916
14
15
18
30
341351011
9687
2955
1
2
High Flow Safety Valves
Bellows design Si 6403
Material code
25
Si 6303Material code 00 01 04
Temperature application range -10 to +450 °C 1) Max. 550 °C -200 to +400 °C 2)
Part Name Spare part Material Material Material
1 Body GP240GH / 1.0619 G17CrMo5-5 / 1.7357 GX5CrNi-Mo19-11-2 / 1.4408
2 Inlet nozzle 7) 1.0460 1.0619 Seat surface hard-faced with Stellite
1.7335 1.7357 Seat surface hard-faced with Stellite
1.4571 1.4408 Seat surface hard-faced with Stellite
3 Stud, short 1.7709 1.7709 A4-70
4 Stud, long 1.7709 1.7709 A4-70
5 Hexagon nut 04 04 04
6 Disc holder 1.0460 5.3106 / GGG-40
1.4571 1.4408
1.4571 1.4408
7 Disc *2, 3 1.4122 Hardened
1.4122 Hardened
1.4571 Seat surface hard-faced with Stellite
8 Disc retainer 1.4571 1.4571 1.4571
9 Groove nut 1.4571 1.4571 1.4571
10 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite 1.4401 / graphite
11 Intermediate cover 9) 1.4122 1.4122 1.4571 1.4408
13 Spring washer, bottom 1.0460 1.4571 1.4571
14 Spring washer, top 1.0460 1.4571 1.4571
15 Bonnet 4) 6) GP240GH / 1.0619 G17CrMo5-5 / 1.7357 5) GX5CrNi-Mo19-11-2 / 1.4408
16 Adjusting screw 1.4122 1.4571 1.4571
17 Lock nut 1.7258 1.7258 1.4571
18 Spindle 1.4122 1.4122 1.4571
19 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite 1.4401 / graphite
20 Cylinder bolt 8.8 8.8 A4-70
23 Packed lifting lever (cap) 3) 1.0619 1.0619 1.4408
24 Lifting nut 1.4401 1.4401 1.4401
29 Bonnet spacer 1.0460 1.7335 1.4571
30 Spring 8) *3 1.1200 1.8159
1.1200 1.8159
1.4310 1.8159, chem. nickel plated
55 Bellows *3 1.4571 1.4571 1.4571
1) Material may be used in temperatures down to -85 °C if the specification of AD 2000-Merkblatt W10 is complied with.
2) Material may be used in temperatures down to -273 °C if the specification of AD 2000-Merkblatt W10 is complied with.
3) Packed lifting lever (cap) from DN 50 x 80 flanged 4) Design Si 61 with open bonnet only for valves
acc. to material code „00“ and „01“.5) Bonnet in GP240GH / 1.0619 for valves Si 61 with
open bonnet, Si 64 with bellows or with design option .15.
6) Si 63 type valves with closed bonnet with design option .15 above 400 °C.
7) Inlet nozzle up to seat ø 77 mm and with weld end option .22a is always manufactured in forging, flow diameter ø 93 mm and above in casting
8) The spring material selection depends on the valve size and set pressure as well as the temperature. Other spring materials are available for special operating conditions, e.g. temperatures > 400 °C or < -170 °C, and if the customer specifies this.
9) Intermediate cover for valves acc. to material code 00 and 01 up to DN 125 x 200 made from 1.4122, above this made from 1.4408.
Spare Parts:*1 For start-up*2 For 2 years of operation*3 After several years of operation All safety valves in pressure class 5 are equipped with a needle bearing between the adjusting screw and upper spring washer.
IMI Bopp & Reuther reserve the right to technical changes or application of higher quality materials without prior notice. The material design can be tailored to customer specifications at any time upon request.
26
Si 6303
High Flow Safety Valves
1) Stated pressures are maximum values corresponding to the spring forces. The component strength may need to be reviewed, and the suitable pressure rating selected, depending on the material and temperature.
2) Or in accordance with the pressure rating at the outlet.
3) 4-hole flange drilling with DN 65 PN 10/164) Drain E is only drilled into the body if condensate
formation is to be expected.
5) Flanges PN 10 - 40 acc. to DIN E 1092 x 2; facing type B1, from PN 63 facing type B2
SizeDNE 25 25 32 40 40 40 50 65 3) 80 80 80 100 125 150 150 200 200 250 300 400
DNA32 40 50 50 65 3) 80 80 100 100 125 150 150 200 200 250 250 300 350 400 500
Flow diameter [mm] d0
16 20 25 25 32 32 40 50 50 63 63 77 93 93 110 125 155 180 220 280
Flow area [mm²] A0
201 314 491 491 804 804 1257 1964 1964 3117 3117 4657 6793 6793 9503 12270 18870 25450 38010 61575
Min. set pres-sure [bar g]
Si 61 / Si 63
0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45
Si 64 / Si 65
2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Max. set pressure 1)
[bar g]62 62 62 62 62 62 62 62 62 50 50 40 25 25 20 12.5 10 8 7 6
Max. back pressure 2) [bar g]
25 24 24 24 24 24 24 24 24 20 20 15 10 10 8 5 4 2.5 2.5 1.25
Inlet flange DIN EN 4)
PN 10 - 40 PN 25 /40 PN 10 - 40
PN 63
PN 100
PN 160
Outlet flange DIN EN 4)
PN 10 /16 /25
PN 40
Centre to face dimen-sion S1 [mm]
95 100 110 110 130 130 145 155 155 190 190 210 215 215 225 240 265 300 335 375
Centre to face dimen-sion S2 [mm]
110 110 115 115 140 140 150 160 175 180 180 200 220 220 245 270 290 340 370 415
Height H1 [mm]
400 420 475 475 535 535 650 685 685 790 790 920 960 960 1020 1125 1210 1400 1480 1650
Height H2 [mm]
475 505 590 590 645 645 765 820 820 940 940 1040 1040 1040 1180 1295 1380 1580 1700 1835
Additional height H3 f. actuator AK [mm]
222 222 205 205 205 205 267 267 267 267 267 394 394 394 394 310 310 490 490 490
Drain size E 5) G¼ G¼ G¼ G¼ G¼ G¼ G¼ G3/8 G3/8 G3/8 G3/8 G3/8 G½ G½ G½ G3/4 G3/4 G3/4 G3/4 G3/4
Weight Si 61/63 [kg]
12 14 19 20 28 35 40 50 52 80 85 126 135 155 170 230 270 370 480 660
Weight Si 64/65 and Si 61/63.15 [kg]
15 17 22 24 32 39 44 55 57 88 93 140 165 185 200 270 320 325 550 745
Additional weight actu-ator AK [kg]
12 12 22 12 12 12 37 37 37 37 37 76 76 76 76 76 76 175 175 175
Sizes, pressure ranges and dimensions
27
Si 6303
B
A E
D
Lø
C
H3
H1
S1
S2
Si 6303 Si 6103
Si 6403 Si 6503
H2
S1
S2
K
Support brackets
Size DNE × DNA
A B C D E LSupport bracket thickness
Number of screws
40 x 65 186 93 140 70 156 14 12 4 x M 12
50 x 80 210 95 165 70 180 14 12 4 x M 12
65 x 100 250 95 205 70 220 14 12 4 x M 12
80 x 125 295 120 240 90 260 18 15 4 x M 16
100 x 150 320 120 265 90 285 18 15 4 x M 16
125 x 200 365 120 300 90 330 18 15 4 x M 16
150 x 250 415 150 360 120 380 18 15 4 x M 16
200 x 250 455 180 400 150 420 18 15 4 x M 16
200 x 300 510 180 450 150 470 23 20 4 x M 20
250 x 350 620 190 560 160 580 23 20 4 x M 20
300 x 400 695 210 600 180 655 23 20 4 x M 20
400 x 500 800 230 715 200 760 23 20 4 x M 20
The height from the inlet to the lower edge of the support bracket is identical with the centre to face dimension S2.
Support brackets will only be drilled if specified by the customer.
The bonnet for bellows seal design is provided with the test connection K. K up to DN 50 x 80 – G¼”, above G⅜”.
Dimensions in mm
Support brackets
Actuator AK
28
Si 6304
23
24
2017
1916
14
15
18
30
3413510119687
1
2
2955
High Flow Safety Valves
Bellows design Si 6404
Material code
29
Si 6304Material code 00 01 04
Temperature application range -10 to +450 °C 1) Max. 550 °C -200 to +400 °C 2)
Part Name Spare part Material Material Material
1 Body GP240GH / 1.0619 G17CrMo5-5 / 1.7357 GX5CrNi-Mo19-11-2 / 1.4408
2 Inlet nozzle 7) 1.0460 1.0619 Seat surface hard-faced with Stellite
1.7335 1.7357 Seat surface hard-faced with Stellite
1.4571 1.4408 Seat surface hard-faced with Stellite
3 Stud, short 1.7709 1.7709 A4-70
4 Stud, long 1.7709 1.7709 A4-70
5 Hexagon nut 04 04 04
6 Disc holder 1.0460 5.3106 / GGG-40
1.4571 1.4408
1.4571 1.4408
7 Disc *2, 3 1.4122 Hardened
1.4122 Hardened
1.4571 Seat surface hard-faced with Stellite
8 Disc retainer 1.4571 1.4571 1.4571
9 Groove nut 1.4571 1.4571 1.4571
10 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite 1.4401 / graphite
11 Intermediate cover 9) 1.4122 1.4122 1.4571 1.4408
13 Spring washer, bottom 1.0460 1.4571 1.4571
14 Spring washer, top 1.0460 1.4571 1.4571
15 Bonnet 4) 6) GP240GH / 1.0619 G17CrMo5-5 / 1.7357 5) GX5CrNi-Mo19-11-2 / 1.4408
16 Adjusting screw 1.4122 1.4571 1.4571
17 Lock nut 1.7258 1.7258 1.4571
18 Spindle 1.4122 1.4122 1.4571
19 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite 1.4401 / graphite
20 Cylinder bolt 8.8 8.8 A4-70
23 Packed lifting lever (cap) 3) 1.0619 1.0619 1.4408
24 Lifting nut 1.4401 1.4401 1.4401
29 Bonnet spacer 1.0460 1.7335 1.4571
30 Spring 8) *3 1.1200 1.8159
1.1200 1.8159
1.4310 1.8159, chem. nickel plated
55 Bellows *3 1.4571 1.4571 1.4571
1) Material may be used in temperatures down to -85 °C if the specification of AD 2000-Merkblatt W10 is complied with.
2) Material may be used in temperatures down to -273 °C if the specification of AD 2000-Merkblatt W10 is complied with.
3) Packed lifting lever (cap) from DN 50 x 80 flanged 4) Si 61 design with open bonnet only for valves
acc. to material code “00” and “01”.5) Bonnet in GP240GH / 1.0619 for valves with open
bonnet Si 61, Si 64 with bellows or with design option .15.
6) Si 63 type valves with closed bonnet with design option .15 above 400 °C.
7) Inlet nozzle up to seat ø 77 mm and with weld end always in forged steel, flow diameter ø 93 mm and above in cast steel.
8) The spring material selection depends on the valve size and set pressure as well as the temperature. Other spring materials are available for special operating conditions, e.g. temperatures > 400 °C or < -170 °C, and if the customer specifies this.
9) Intermediate cover for valves acc. to material code 00 and 01 up to DN 125 x 200 made from 1.4122, above this made from 1.4408.
Spare Parts:*1 For start-up*2 For 2 years of operation*3 After several years of operationAll safety valves in pressure class 5 are equipped with a needle bearing between the adjusting screw and upper spring washer.
IMI Bopp & Reuther reserve the right to technical changes or application of higher quality materials without prior notice. The material design can be tailored to customer specifications at any time upon request.
30
Si 6304
High Flow Safety Valves
SizeDNE 25 32 40 40 40 50 65 3) 80 80 80 100 125 150 150 200 200 250 300
DNA40 50 50 65 3) 80 80 100 100 125 150 150 200 200 250 250 300 350 400
Flow diameter [mm] d0
16 20 20 25 25 32 40 40 50 50 63 77 77 93 110 125 155 180
Flow area [mm²] A0
201 314 314 491 491 804 1257 1257 1964 1964 3117 4657 4657 6793 9503 12270 18870 25450
Min. set pres-sure [bar g]
Si 61 / Si 63
0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45
Si 65 / Si 64
2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Max. set pressure 1)
[bar g]95 95 95 95 95 95 95 95 78 78 62 40 40 32 20 16 12 10
Max. back pressure 2) [bar g]
24 24 24 24 24 24 24 24 20 20 15 10 10 8 5 4 3 3
Inlet flange DIN EN 4)
PN 25 /40 PN 25
PN 63
PN 100
PN 160 PN 160
Outlet flange DIN EN 4)
PN 10 /16
PN 25 /40 PN 25
Centre to face dimen-sion S1 [mm]
100 110 110 130 130 145 155 155 190 190 210 215 215 225 240 265 300 335
Centre to face dimen-sion S2 [mm]
120 125 125 140 140 150 165 175 185 185 200 220 260 245 270 290 340 370
Height H1 [mm]
430 485 485 535 535 650 680 680 795 795 940 960 960 1020 1125 1210 1210 1480
Height H2 [mm]
515 580 580 645 645 765 815 815 945 945 1060 1080 1080 1180 1295 1380 1580 1700
Additional height H3 f. actuator AK [mm]
222 205 205 205 205 267 267 267 267 267 394 394 394 394 310 310 490 490
Drain size E 5) G¼ G¼ G¼ G¼ G¼ G¼ G⅜ G⅜ G⅜ G⅜ G⅜ G½ G½ G½ G¾ G¾ G¾ G¾
Weight Si 61/63 [kg]
14 19 20 28 30 40 50 52 80 85 126 135 140 170 230 270 370 480
Weight Si 64/65 and Si 61/63.15 [kg]
17 22 24 32 34 44 55 57 88 93 140 165 170 200 270 320 425 550
Additional weight actu-ator AK [kg]
12 12 12 12 12 37 37 37 37 37 76 76 76 76 76 76 175 175
1) Stated pressures are maximum values corresponding to the spring forces. The component strength may need to be reviewed, and the suitable pressure rating selected, depending on the material and temperature.
2) Or in accordance with the pressure rating at the outlet.
3) 4-hole flange drilling with DN 65 PN 10/164) Drain E is only drilled into the body if condensate
formation is to be expected.
5) Flanges acc. to DIN EN 1092-1; facings up to PN 40 type B 1, from PN 63 type B 2
Sizes, pressure ranges and dimensions
31
Si 6304
B
A E
D
Lø
C
H3
H1
S1
S2
Si 6304 Si 6104
Si 6404 Si 6504
H2
S1
S2
K
Support brackets
Size DNE × DNA
A B C D E LSupport bracket thickness
Number of screws
40 x 65 186 93 140 70 156 14 12 4 x M 12
50 x 80 210 95 165 70 180 14 12 4 x M 12
65 x 100 250 95 205 70 220 14 12 4 x M 12
80 x 125 295 120 240 90 260 18 15 4 x M 16
100 x 150 320 120 265 90 285 18 15 4 x M 16
125 x 200 365 120 300 90 330 18 15 4 x M 16
150 x 250 415 150 360 120 380 18 15 4 x M 16
200 x 250 455 180 400 150 420 18 15 4 x M 16
200 x 300 510 180 450 150 470 23 20 4 x M 20
250 x 350 620 190 560 160 580 23 20 4 x M 20
300 x 400 695 210 600 180 655 23 20 4 x M 20
The height from the inlet to the lower edge of the support bracket is identical with the centre to face dimension S2.
Support brackets will only be drilled if specified by the customer.
The bonnet for bellows seal design is provided with the test connection K. K up to DN 50 x 80 – G¼”, above G⅜”.
Dimensions in mm
Support brackets
Actuator AK
32
Si 6305
23
24
20
17
1916
14
15
18
30
4
135310
119687
1
2
2955
High Flow Safety Valves
Bellows design Si 6405
Material code
33
Si 6305Material code 00 01
Temperature application range -10 to + 450 °C 1) Max. 550 °C
Part Name Spare part Material Material
1 Body GP240GH / 1.0619 G17CrMo5-5 / 1.7357
2 Inlet nozzle 5) 1.0460 1.0619 Seat surface hard-faced with Stellite
1.7335 1.7357 Seat surface hard-faced with Stellite
3 Stud, short 1.7709 1.7709
4 Stud, long 1.7709 1.7709
5 Hexagon nut 04 04
6 Disc holder 1.0460 5.3106 / GGG-40
1.4571 1.4408
7 Disc *2, 3 1.4122 Hardened
1.4122 Hardened
8 Disc retainer 1.4571 1.4571
9 Groove nut 1.4571 1.4571
10 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite
11 Intermediate cover 7) 1.4122 1.4122
13 Spring washer, bottom 1.0460 1.4571
14 Spring washer, top 1.0460 1.4571
15 Bonnet 4) GP240GH / 1.0619 G17CrMo5-5 / 1.7357 3)
16 Adjusting screw 1.4122 1.4571
17 Locknut 1.7258 1.7258
18 Spindle 1.4122 1.4122
19 Flat gasket *1, 2, 3 1.4401 / graphite 1.4401 / graphite
20 Cylinder bolt 8.8 8.8
23 Packed lifting lever (cap) 2) 1.0619 1.0619
24 Lifting nut 1.4401 1.4401
29 Intermediate spacer 1.0460 1.7335
30 Spring 6) *3 1.1200 1.8159
1.1200 1.8159
55 Bellows *3 1.4571 1.4571
1) Material may be used in temperatures down to -85 °C if the specification of AD 2000-Merkblatt W10 is complied with.
2) Packed lifting lever (cap) from DN 50 x 80 flanged3) Bonnet in GP240GH / 1.0619 for valves with open
bonnet Si 61, with bellows Si 64 or with design option .15.
4) Si 63 type valves with closed bonnet require design option .15 above 400 °C.
5) Inlet nozzle up to seat ø 77 mm and with weld end option .22a is always manufactured in forging, flow diameter ø 93 mm and above in casting.
6) The spring material selection depends on the valve size and set pressure as well as the temperature. Other spring materials are available for special operating conditions, e.g. temperatures > 400 °C or < -170 °C, and if the customer specifies this.
7) Intermediate cover for valves acc. to material code 00 and 01 up up to DN 125 x 200 from 1.4122, above this from 1.4408.
Spare Parts:*1 For start-up*2 For 2 years of operation*3 After several years of operationAll safety valves in pressure class 5 are equipped with a needle bearing between the adjusting screw and upper spring washer.
IMI Bopp & Reuther reserve the right to technical changes or application of higher quality materials without prior notice. The material design can be tailored to customer specifications at any time upon request.
34
Si 6305
High Flow Safety Valves
SizeDNE 25 40 40 50 65 3) 80 100 125 150 200 200 250 300 350 400
DNA40 50 65 3) 80 100 125 150 200 250 250 300 350 400 500 500
Flow diameter [mm] d0
16 20 25 32 40 50 63 77 93 110 125 155 180 220 255
28 36 46 56 70 86 98 117 140 168 200 235 280
Flow area [mm²] A0
201 314 491 804 1257 1964 3117 4657 6793 9503 12270 1887 25450 38010 51070
615 1018 1662 2463 3848 5809 7543 10750 15390 22170 31420 43370 61575
Min. set pres-sure [bar g]
Si 61 / Si 63
0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45
Si 64 / Si 65
2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Max. set pressure 1)
[bar g]
250 250 230 220 180 145 115 77 53 43 33 23 18 12 10
220 200 160 130 93 62 48 38 26 20 14 10 8
Max. back pressure 2) [bar g]
40 40 40 40 40 40 24 16 12 10 8 6 4 3 2
35
Inlet flange DIN EN 4)
PN 25 /40 PN 25 PN 10 - 25
PN 63 - 160 PN 63 / 100 PN 63 PN 40
PN 250
PN 320
PN 400
Outlet flange DIN EN 4)
PN 25 / 40 PN 10 - 25 PN 10 / 16 PN 10
PN 63
PN 100
Centre to face dimen-sion S1 [mm]
150 160 190 225 235 235 245 260 260 265 265 300 335 375 375
Centre to face dimen-sion S2 [mm]
150 160 170 190 220 220 220 260 290 300 340 355 370 415 415
Height H1 [mm]
640 660 760 910 950 970 1040 1100 1150 1210 1260 1415 1480 1640 1640
Height H2 [mm]
755 795 910 1060 1090 1110 1185 1230 1280 1380 1430 1595 1695 1825 1825
Additional height H3 f. actuator AK [mm]
267 267 267 324 324 324 240 240 240 490 490 490 490 490 490
Drain size E 5) G¼ G¼ G¼ G¼ G⅜ G⅜ G⅜ G⅜ G½ G½ G¾ G¾ G¾ G¾ G¾
Weight Si 61/63 [kg]
42 57 83 110 120 175 205 230 245 280 320 400 500 630 680
Weight Si 64/65 and Si 61/63.15 [kg]
46 62 88 115 127 185 222 263 281 330 385 478 590 735 785
Additional weight actuator AK [kg]
37 37 37 80 80 80 80 80 80 175 175 175 175 175 175
1) Stated pressures are maximum values corresponding to the spring forces. The component strength may need to be reviewed, and the suitable pressure rating selected, depending on the material and temperature.
2) Or in accordance with the pressure rating of the outlet.
3) 4-hole flange drilling with DN 65 PN 10/164) Drain E is only drilled into the body if condensate
formation is to be expected.
5) Flanges acc. to DIN EN 1092-1; facings up to PN 40 type B 1, from PN 63 type B 2.
Sizes, pressure ranges and dimensions
35
B
A E
D
Lø
C
H3
H1
S1
S2
Si 6305 Si 6105
Si 6405 Si 6505
H2
S1
S2
K
Si 6305
Support brackets
Size DNE × DNA
A B C D E LSupport bracket thickness
Number of screws
40 x 65 250 70 175 45 220 14 13 4 x M 12
50 x 80 315 80 230 55 280 18 13 4 x M 16
65 x 100 346 165 285 140 310 18 15 4 x M 16
80 x 125 355 165 290 140 320 18 15 4 x M 16
100 x 150 365 165 300 140 330 18 15 4 x M 16
125 x 200 400 170 340 135 360 18 15 4 x M 16
150 x 250 472 180 410 150 434 18 15 4 x M 16
200 x 250 516 180 460 150 480 18 15 4 x M 16
200 x 300 510 180 450 145 465 22 20 4 x M 20
250 x 350 620 190 560 160 580 22 20 4 x M 20
300 x 400 695 210 600 180 655 22 20 4 x M 20
400 x 500 800 230 715 200 760 22 20 4 x M 20
The height from the inlet to the lower edge of the support bracket is identical with the centre to face dimension S2.
Support brackets will only be drilled if specified by the customer.
The bonnet for bellows seal design is provided with the test connection K. K up to DN 50 x 80 – G¼”, above G⅜”.
Dimensions in mm
Support brackets
Actuator AK
36
Si 6106
High Flow Safety Valves
The IMI Bopp & Reuther high pressure steam safety valve:
> Solid inlet nozzle, screwed in and welded
> Manages the high forces in the pressure adjustment via clamping plate and upper pressure ring
> Material designs for high temperatures with the option to select the material at
the inlet in accordance with customer specifications
> Ideal for combination with the pneumatic actuator AK as well as the PC 50 / 53 control unit for “controlling” the discharge process
Features
Inlet sizesDN 80 to DN 300
Inlet pressure ratingPN 40 to PN 400
Set pressures15 bar g to 200 bar g
Temperature rangeUp to 550 °C
OverpressureVapours / gases 5%
Blow downVapours / gases 10%
Allowable built-up back pressure25% of the set pressure
> Steam boiler
> Superheater
> Power plants and industrial steam generators
> Steam temperatures above 500 °C
> Large flow diameter with high pressures
Applications
Approvals and standards
EC type examination
- Pressure Equipment Directive 97 / 23 / EC
- DIN EN ISO 4126-1
- AD 2000-Merkblatt A2
- VdTÜV Merkblatt “Sicherheitsventil 100”
VdTÜV type approval acc. to
TÜV.SV.10 -138.d0.D / G.aw.p
IMI Bopp & Reuther will not renew the existing VdTÜV type approvals. The requirements by VdTÜV and applicable standards are completely considered by the EC type examination.
The design, manufacture, testing and labelling meet the requirements of DIN EN ISO 4126-7, DIN EN 12266-1 / -2 (insofar as applicable to safety valves), DIN EN 1092 parts I and II Flanges, AD 2000-Merkblatt A4, AD 2000-Merkblatt HP0, technical rules for steam boiler TRD 110, TRD 421
Safe operation with 25% back pressure
Full nozzle design
Engineered specific for HP steam application
37
Si 6106
Type code Order example
1 Series Si 6 DIN/EN Full lift valve Si 6
2 Design 1 Conventional, open bonnet 1
3 Characteristic 0 High capacity "High Flow" 0
4 Pressure class 6 Up to PN 400 6
5 Cap AB Lifting lever with test gag AK
AK Pneumatic actuator
6 Material code 2) 00 GP240GH / 1.0619 00
01 G17CrMo5-5 / 1.7357
11 G17CrMo9-10 / 1.7379
7 Options .09 Locking sleeve (government ring) .22a
.14a Lift indication with inductive proximity switch in the cap
.14b Lift indication with inductive proximity switch in the auxiliary housing
.14c Lift indication with inductive proximity switch for exposed spindle with actuator AK
.22a Weld end at inlet
.22b Weld end at outlet
.25 Block body design
.35 Lift restriction ring
.59 Stellited disc
.60 Stellited seat
1) For valves with weld ends, please state the pipe’s outer diameter, wall thickness and joint type code in your order. See page 39 for information on standard dimensions.
2) The standard materials of the material codes can be changed by selecting trim codes. Please see page 44 for information on our trim codes T1, T2, T3.
Si 6106 AK 00 .22a
Set pressure 105 bar gFluid temp. 400 °CFluid Superheated steam, and State SteamInlet DN 100, weldendWeld end dimensions1) 117 x 14.2 mmOutlet DN 150, PN 100, B2Flow diameter 63 mmApproval 97 / 23 / EG (CE)
Type
Please state
Type code
38
Si 6106
High Flow Safety Valves
Fluid group Inlet size Flow diameter h/d0 ≥ pb/p0 ≤ aw
Vapours / gases (D / G)DN 80 to DN 200
DN 250 to DN 300
56 mm up to 140 mm
155 mm up to200 mm
0.36
0.38
0.25
0.3
0.81
0.78
The coefficient of discharge for gases/vapours in a pressure ratio of pb/p0 > 0.25 and/or pb/p0 > 0.3 is shown in the diagram below.
The capacity of the selected safety valves can be adjusted to the required capacity by reducing the lift, thus reducing undesirable extra performance. The following applies:
aw(reduced) = aw x qm/qmc. The required ratio h/d0 is shown in the diagram below, and the reduced lift calculated with h(reduced) = d0 x (h/d0).
Si 6106 coefficient of discharge aw depending on pb/p0 for gases and vapours
Si 6106 coefficient of discharge aw depending on h/d0 for gases and vapours
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.00 0.10 0.20 0.30 0.40
αw
[−]
h/d0 [−]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.00 0.10 0.20 0.30 0.400.00 0.10 0.25 0.30 0.40
h/d0[–]
0.25
0.9
0.8
0.7
0.6
0.4
0.3
0.2
aw
[–]
0.1
0.0
d0 = 56-140 mm d0 = 155-200 mm
0.5
h = Lift [mm]d0 = Flow diameter of the selected safety valve [mm]h/d0 = Lift/Flow diameter ratiopb = Absolute back pressure [bar a]p0 = Absolute relieving pressur [bar a]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
αW
[−]
pa/p0 [−]
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
aw
[–]
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
pb/p0[–]
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
d0 = 56-140 mm d0 = 155-200 mm
pb/p0 = Absolute back pressure / absolute relieving pressure ratioaw = Coefficient of discharge acc. to AD 2000-Merkblatt A2qm = Required mass flow [kg/hr]qmc = Certified mass flow [kg/hr]
Sizes, pressure ranges and dimensions
39
Weld ends are mainly used for applications with high pressure and high temperatures. The following table shows the standard IMI Bopp & Reuther dimensions acc. to DIN EN 12627. This European standard defines the dimensions for weld ends of steel valves that are welded to standardi-zed pipes. The outside diameters and wall thicknesses of the standardized pipes are described in DIN EN 1092-1.
The shape and dimensions of weld ends can be changed upon request.
Specification of the weld end (must be stated in your order)
1. Inlet nozzle material
2. Weld end dimensions
2. 1 Outer diameter D
2. 2 Wall thickness S
The centre to face dimensions S2 for safety valves with weld end are as a standard identical with the centre to face dimensions of the same type with flange at the inlet. The centre to face dimensions can also be tailored to customer specifications.
Example: Weld end P 250 GH (1.0460); 114.3 x 3.6 (acc. to DN 100 PN 40)
Weld end
Standard dimensions
DN ØD [mm] DIN EN 12627
PipeØ [mm] DIN EN 1092-1
Wall thickness S [mm]
PN 16 PN 25 PN 40 PN 63 PN 100 PN 160 PN 250 PN 320
15 22 21.3 2.0 2.0 2.0 2.0 3.2 3.2 3.2 3.2
20 28 26.9 2.3 2.3 2.3 2.6 3.2 n. v. n. v. n. v.
25 35 33.7 2.6 2.6 2.6 2.6 3.6 3.6 3.6 5.0
32 44 42.4 2.6 2.6 2.6 2.9 3.6 n. v. n. v. n. v.
40 50 48.3 2.6 2.6 2.6 2.9 3.6 3.6 5.0 6.3
50 62 60.3 2.9 2.9 2.9 4.0 4.0 4.0 6.3 8.0
65 77 76.1 2.9 2.9 2.9 4.0 4.0 5.0 8.0 11.0
80 91 88.9 3.2 3.2 3.2 4.5 5.0 6.3 11.0 12.5
100 117 114.3 3.6 3.6 3.6 4.5 5.6 8.0 14.2 16.0
125 144 139.7 4.0 4.0 4.0 5.6 6.3 10.0 16.0 20.0
150 172 168.3 4.5 4.5 4.5 6.3 8.0 12.5 17.5 25.0
200 223 219.1 6.3 6.3 6.3 7.1 8.8 16.0 25.0 30.0
250 278 273.0 6.3 7.1 7.1 8.8 10.0 20.0 32.0 40.0
300 329 323.9 7.1 8.0 8.0 11.0 12.5 22.2 n. v. n. v.
350 362 355.6 8.0 8.0 8.8 12.5 14.2 n. v. n. v. n. v.
400 413 406.4 8.0 8.8 11.0 14.2 16.0 n. v. n. v. n. v.
S2
DS
Weld end with V-seam for connection to a pipe with wall thickness 4 < S ≤ 22 mm
Body centre
Welding joint acc. to DIN EN ISO 9692-1
Weld end (option .22) for Si 6106, as well as the series Si 6303, Si 6304 and Si 6305
n. a. not available
40
Si 6106
23
24
19
20
17
15/3
14
16
18
3015/2
13
43
515/1
10
11
9
6
7
1
2
50
47
55
48
8
High Flow Safety Valves
Section / detail Si 6106
Material code
41
Si 6106Material code 00 01 11
Temperature application range -10 to +450 °C Max. 530 °C Max. 600 °C
Part Name Spare part Material Material Material
1 Body GP240GH / 1.0619 G17CrMo5-5 / 1.7357 G17CrMo9-10 / 1.7379
2 Inlet nozzle P250GH / 1.0460 Seat surface hard-faced with Stellite
13CrMo4-5 / 1.7335 Seat surface hard-faced with Stellite
10CrMo9-10 / 1.7380 Seat surface hard-faced with Stellite
3 Stud, short 1.7709 1.7709 1.7709
4 Stud, long 1.7709 1.7709 1.7709
5 Hexagon nut 1.7258 1.7258 1.7258
6 Lift collar 1.0460 1.4122 1.4122
7 Disc 1) *2 1.4122 Hardened 1.4122 Hardened 1.4122 Hardened
8 Locking ring 1.7380 1.7380 1.7380
9 Guiding bush *3 1.4122 Hardened 1.4122 Hardened 1.4122 Hardened
10 Flat gasket 1.4401 / graphite 1.4401 / graphite 1.4401 / graphite
11 Intermediate cover 1.4122 1.4122 1.4122
13 Spring washer, bottom 1.4122 1.4122 1.4122
14 Spring washer, top 1.4122 1.4122 1.4122
15 / 1 Lower bonnet flange 1.0425 1.0425 1.0425
15 / 2 Bonnet cylinder 1.0305 1.0305 1.0305
15 / 3 Upper bonnet flange 1.0425 1.0425 1.0425
16 Holding bushing 1.4122 1.4122 1.4122
17 Clamping plate 1.4122 1.4122 1.4122
18 Spindle 1.4122 1.4122 1.4122
19 Hexagon nut 8.8 8.8 8.8
20 Cylinder bolt 1.0109 1.0109 1.0109
23 Lifting lever (cap) 1.0460 1.0460 1.0460
24 Lifting nut 1.4122 1.4122 1.4122
30 Spring 1.8159 1.8159 1.8159
47 Piston ring *2 1.4086 1.4086 1.4086
48 Guide ring *3 1.4086 1.4086 1.4086
50 Cap nut 1.4122 1.4122 1.4122
55 Piston ring guide 1.4122 1.4122 1.4122
1) 1.4122 hardened, running surfaces hard chrome plated
Spare Parts:*1 For start-up*2 For 2 years of operation*3 After several years of operation
IMI Bopp & Reuther reserve the right to technical changes or application of higher quality materials without prior notice. The material design can be tailored to customer specifications at any time upon request.
42
Si 6106
High Flow Safety Valves
SizeDNE 80 100 100 125 125 150 150 200 200 200 200 250 250 300 300
DNA150 150/200 150/200 250 250 250 250 250 250 300 300 350 350 400 400
Flow diameter [mm] d0
56 63 70 77 86 93 98 110 117 125 140 155 168 180 200
Flow area [mm²] A0
2463 3117 3848 4657 5809 6793 7543 9503 10751 12272 15394 18869 22167 25447 31416
Min. set pressure [bar g]
70 60 60 50 50 40 40 30 30 25 25 15 15 15 15
Max. set pressure1)
[bar g]
200 180 180 150 150 125 125 100 100 75 75 50 50 45 45
(95) 2) (85) 2) (65) 2) (60) 2) (54) 2) (44) 2) (35) 2)) (31) 2) (26) 2) (20) 2)
Max. back pressure [bar g]
30 27 27 22.5 22.5 18.7 18.7 15 15 11.2 11.2 7.5 7.5 6.7 6.7
Inlet flange DIN EN 3)
PN 100 PN 100 PN 40 / 63
PN 160
PN 250
PN 400
Outlet flange DIN EN 3)
PN 16 PN 16 / 10
PN 40 PN 25 / 40 PN 25
PN 63 / 100 PN 63
Centre to face dimen-sion S1 [mm]
290 290 330 300 300 295 295 340 340 305 305 400 400 455 455
Centre to face dimen-sion S2 [mm]
260 270 280 330 330 400 400 335 335 360 360 375 375 440 440
Height H1 [mm]
1400 1400 1400 1400 1400 1400 1400 1600 1600 1600 1600 1850 1850 2000 2000
Additional height H3 f. actuator AK [mm]
490 490 490 490 490 490 490 490 490 490 490 490 490 490 490
Drain size E 4) G½ G½ G½ G½ G½ G½ G½ G½ G½ G½ G½ G½ G½ G½ G½
Weight Si 61 [kg]
220 250 250 285 285 305 305 305 355 400 400 510 510 890 910
Additional weight actu-ator AK [kg]
175 175 175 175 175 175 175 175 175 175 175 175 175 175 175
1) Stated pressures are maximum values corresponding to the spring forces. The component strength may need to be reviewed depending on the material and temperature.
2) Maximum set pressure if the pneumatic actuator AK is used. Up to this pressure, the actuator force is sufficient for obtaining the desired function improvement.
3) Flanges: acc. to DIN EN 1092-1; gasket facing up to PN 40 type B1, PN 63 and above type B2.
4) Drain E is only drilled into the body if condensate formation is to be expected.
Sizes, pressure ranges and dimensions
43
Si 6106
BA E
D
Lø
C
H3
H1
S1
S2
Si 6106Support brackets
Size DNE × DNA
A B C D E LSupport bracket thickness
Number of screws
80 x 150 350 120 265 75 305 22 20 4 x M 20
100 x 150 460 160 350 130 420 22 25 4 x M 20
100 x 200 450 140 340 90 390 27 25 4 x M 24
125 x 250 560 170 405 100 480 30 30 4 x M 27
150 x 250 550 210 420 150 480 33 35 4 x M 30
200 x 250 580 210 420 150 500 33 25 4 x M 30
200 x 300 600 210 420 150 530 33 25 4 x M 30
250 x 350 690 210 520 150 600 33 25 4 x M 30
300 x 400 820 270 660 200 730 39 35 4 x M 36
The height from the inlet to the lower edge of the support bracket is identical with the centre to face dimension S2.
Support brackets will only be drilled if specified by the customer.
Support brackets
Actuator AK
Dimensions in mm
44
200 250 300 350 400 450 500 550 600
300
250
200
150
100
50
0
PN 400
PN 250
PN 250PN 250
PN 160
PN 160
PN 100PN 100
PN 100
PN 63
PN 63
PN 63
PN 63
PN 100
PN 100 PN 63
PN 160
PN 160
PN 160
PN 250
PN 250
PN 400PN 400
PN 400
PN 400
High Flow Safety Valves
Trim codeTrim codes stand for the replacement of standard materials of named “trim parts” and allow the selected safety valve being suitable for special operating conditions. The trim codes T1 to T3 can increase the temperature application range of the
selected safety valve and therewith enable its use in high operating and discharge temperatures. With the series Si 6303 to Si 6106, the pressure of the system to be protected is applied to the one-piece solid inlet nozzle. Selecting a more temperature-
resistant material for the inlet nozzle can for example permit the selection of a lower inlet pressure rating or more economic material class.
1) Or made from equivalent cast material, see material list of the series
2) Materials of Si 6xx3-5 usable in up to 550 °C 3) Seat surface hard-faced with Stellite
The diagram below shows the maximum pressure / temperature graphs of the materials available for the inlet nozzle. The design-related maximum set pressure of every series and size acc. to table “Sizes, pressure ranges and dimensions” must be taken into account over and beyond this.
Example: Si 6105 A 00, DN 65 x 100, PN 250 x 40, flow diameter 46 mm, can be used up to a maximum set pressure of 142 bar g at a discharge temperature of 400 °C.
With selection of trim code T3, the Si 6105 A 00-T3 safety valve can be used up to a maximum set pressure of 160 bar g, max. set pressure acc. to material characteristic 186 bar g, but series / size limited to 160 bar g; see table on page 34.
Series Material Code
Body material Trim code Material Inlet nozzle
Maximum application temperature
Si 6xx3-5 00 1.0619 GP240GH Standard 1.0460 1) 3) P250GH Up to 450 °C
Si 6106 T3 1.5415 3) 16Mo3 Up to 450 °C
Si 6xx3-5 01 1.7357 G17CrMo5-5 Standard 1.7335 1) 3) 13CrMo4-5 Up to 530 °C 2)
Si 6106 T2 1.7380 3) 10CrMo9-10 Up to 530 °C 2)
Si 6106 11 1.7379 G17Cr-Mo9-10
Standard 1.7380 3) 10CrMo9-10 Up to 600 °C
T1 1.4903 3) X10CrMoVNb9-1 Up to 600 °C
Trim code T3 T2 T1
Body 1.0619 / GP240GH 1.7357 / G17CrMo5-5 1.7379 / G17CrMo9-10
Inlet nozzle standard: 1.0460 / P250GH 1.7335 / 13CrMo4-5 1.7380 / 10CrMo9-10
Inlet nozzle trim code: 1.5415 / 16Mo3 1.7380 / 10CrMo9-10 1.4903 / X10CrMoVNb9-1
Temperature [°C]
Set pressure [bar g]
Max. set pressure Si 6105
Max. set pressure Si 6106
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Controlled safety valve
Spring-loaded safety valves are often unable to meet operating conditions such as a high operating pressure (> 90% of set pressure), stringent tightness requirements up to the set pressure, or reduced opening and reseat pressure difference.
With the pneumatic actuator AK and control units PC 50 or PC 53, the spring safety valve is turned into a controlled safety valve (CSPRS acc. to EN ISO 4126-5).
The control unit requires an external air supply. The triple redundant pressure switches of the control unit are connected with the pressure system to be protected and control the compressed air supply at the AK piston in accordance with their set pressure.
The loading air in the actuator AK increases the closing force up to the set pressure; activation of the optional lift air supports and stabilizes the discharge process.
The rules for sizing calculation of the required flow diameter correspond to the rules for spring-loaded valves. The series Si 4302 and Si 6303 to Si 6106 can be combined with an actuator AK.
Please see the IMI Bopp & Reuther catalogue “Pneumatic Control Unit PC 50” for more detailed information.
The pneumatic actuator AK follows the relief principle and uses differential surface pistons of a “flying piston” design. This ensures frictionless opening as a spring safety valve if the air supply fails.
The safety valve will no longer be gastight at the upper end of the bonnet once the actuator is set up. If a gastight design is required (typically for all applications except steam), a bellows design will need to be selected.
Part Name Material
60 Bonnet plate P250GH / 1.0460
61 Coupling 1.0038
62 Column GX35CrMo / 1.4122
63 Locking nut 1.0109
64 Spindle GX35CrMo / 1.4122
65 Piston bushing P250GH / 1.0460 (hard chrome-plated)
66 Lifting pistonGX35CrMo / 1.4122 size 1+2 GP240GH / 1.0619 size 3-5 (coated with zinc dust paint)
67 Loading pistonGX35CrMo / 1.4122 size 1+2 GP240GH / 1.0619 size 3-5 (coated with zinc dust paint)
68 Cover P250GH / 1.0460
70 Spring 1.8159
Controlled safety pressure relief system
Pneumatic actuator AK
46
High Flow Safety Valves
.18 Heating jacket with flange connection for safety valve with bellows
.18 Heating jacket with threaded connection for safety valve with bellows
.18 Heating jacket with flange connection for conventional safety valve
Heating jacket
Hardening or solidification of highly viscous media in the safety valve can interfere with the function or closing and hence lead to dangerous operating conditions. Media with a tendency to conglutination or crystallization can block the seat and moving parts. This can usually be remedied by maintaining the temperature of the Fluid before and during the discharge. Monitoring and heating the
pipe will often not provide the required heat to the inlet of the safety valve. Equipping the safety valve with a heating jacket will solve this problem. Typical applications for safety valves with heating jacket (option code .18) include ammonium nitrate, acrylic acid, sulphuric acid, fluoropolymers, polypropylene, olefins, and tar.
The safety valve should be equipped with bellows to protect the spindle and guides.
Additional heating of the isolating spacer is integrated in the heating circuit by means of piping. The bellows will not be required if the fluid does not tend to solidify in the outlet of the safety valve.
Purging the seat area with steam can serve as a further measure for protecting the safety valve seat from conglutination. The purge connection (option .32) can also be combined with the heating jacket.
1) Nominal pressure rating for the heating jacket at 50 °C. The heating jacket is labelled in compliance with the Pressure Equipment Directive.
2) Depending on the heating jacket design or availability of materials, we reserve the right to use higher quality 1.4404 or 1.4571 stainless steel.
Other connections, pressure ratings or materials available upon request. Safety valves with heating jacket have no support brackets.
Safety valve Inlet size
DNE25 32 40 50 65 80 100 150 200 ≥ 250
Heating jacket connection
Flange DN 15 PN 25 DN 25 PN 25
Thread G3/8 G3/4
Max. heating jacket working pressure [bar g] 1)
50 °C 25 16 10
150 °C 22 14 9
200 °C 21 13 8
300 °C 18 12 7
Heating jacket material Stainless steel 1.4301 2)
Safety valve with heating jacket (Option .18)
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Options
B Test gag: Blocking of the safety valve for pressure testing the pressure system.
.11 Disc with soft seal for particularly high tightness.
.14a Lift indication with inductive proximity switch in the cap. If the safety valve disc lifts by 1 mm minimum, the proximity switch will change its status and switch.
.57 Weight load for operation with very low set pressure.
.38 Vibration damper for avoiding valve oscillation in case of unfavourable installation conditions.
.22a Weld end at inlet.
.15 Bonnet insulation spacer for protecting the spring against high and low temperatures.
.32 Purge connection for constant cleaning of the safety valve seat and hence protecting it from conglutination.
.14c Lift indication with inductive proximity switch for exposed spindle with actuator AK. If the safety valve disc lifts by 1 mm minimum, the proximity switch will change its status and switch.
Technical design options
IMI Critical Engineering Lakeside, Solihull Parkway Birmingham Business Park Birmingham B37 7XZ United Kingdom
Tel: +44 (0)121 717 3700 Fax: +44 (0)121 717 3701
www.imi-critical.com
IMI Bopp & Reuther Bopp & Reuther Sicherheits- und Regelarmaturen GmbH Carl-Reuther-Straße 1 68305 Mannheim Deutschland
Tel: +49 (0)621 76220-100 Fax: +49 (0)621 76220-120
www.imi-critical.com [email protected]
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